Apparatuses, methods, and systems for vibratory screening

ABSTRACT

Vibratory screening machines that include stacked screening deck assemblies are provided. In some embodiments, at least one of the vibratory screening machines may include an outer frame, an inner frame connected to the outer frame, and a vibratory motor assembly secured to the inner frame for vibrating the inner frame. A plurality of screen deck assemblies may be attached to the inner frame in a stacked arrangement, each configured to receive replaceable screen assemblies. The screen assemblies may be secured to respective ones of the plurality of the screen deck assemblies by tensioning the screen assemblies in a direction that a material to be screened flows across the screen assemblies. An undersized material discharge assembly may be configured to receive materials that pass through the screen assemblies, and an oversized material discharge assembly having a deflector may be configured to receive materials that pass over the screen assemblies.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/460,764, filed Jul. 2, 2019, which is a continuation-in-part of U.S.patent application Ser. No. 15/785,141, filed Oct. 16, 2017, which isrelated to and claims the benefit of U.S. Provisional Patent ApplicationNo. 62/408,514, filed Oct. 14, 2016, and U.S. Provisional PatentApplication No. 62/488,293, filed Apr. 21, 2017. This application isalso related to U.S. Design Application No. 29/644,138, filed Apr. 15,2018. The disclosure of each of these applications is incorporatedherein by reference in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective side view of a vibratory screening machine,according to one or more embodiments of the present disclosure.

FIG. 2 is a perspective top view of the vibratory screening machineshown in FIG. 1 .

FIG. 3 is a front view of the vibratory screening machine shown in FIGS.1 and 2 .

FIG. 4 is a rear view of the vibratory screening machine shown in FIGS.1, 2, and 3 .

FIG. 5 is an isometric view of a screening deck having screen assembliesmounted thereon, according to one or more embodiments of the presentdisclosure.

FIG. 6 is an enlarged partial isometric view of the screening deck shownin FIG. 5 , without screen assemblies mounted thereon, incorporated intothe vibratory screening machine shown in FIGS. 1, 2, 3, and 4 .

FIG. 7 is an enlarged side view of a wash tray, which may beincorporated into the screening deck shown in FIGS. 5 and 6 , accordingto one or more embodiments of the present disclosure.

FIG. 8 is an isometric view of a tensioning device with a ratchetmechanism, according to one or more embodiments of the presentdisclosure.

FIG. 9A is a side view of the screening deck shown in FIGS. 5, 6, and 7with the ratchet mechanism shown in FIG. 8 .

FIG. 9B is an enlarged view of the ratchet mechanism shown in FIG. 9A.

FIG. 10 is an enlarged partial isometric view of a feed assembly and thescreening deck shown in FIGS. 5, 6, and 7 secured to the vibratoryscreening machine shown in FIGS. 1, 2, 3 and 4 .

FIG. 11A is an isometric bottom view of an undersized material dischargeassembly, according to one or more embodiments of the presentdisclosure.

FIG. 11B is an isometric top view of the undersized material dischargeassembly shown in FIG. 11A.

FIG. 12A is an isometric bottom view of an oversized material dischargechute, according to one or more embodiments of the present disclosure.

FIG. 12B is an isometric top view of the oversized material dischargechute shown in FIG. 12A.

FIG. 13A is an isometric top view of an oversized material dischargetrough, according to one or more embodiments of the present disclosure.

FIG. 13B is an isometric bottom view of the oversized material dischargetrough shown in FIG. 13A, according to one or more embodiments of thepresent disclosure.

FIG. 14 is a cross-sectional side view of a screening deck havingmaterial flowing across the screening deck and featuring an impact areaof a screen assembly incorporated into a screening deck assembly,according to one or more embodiments of the present disclosure.

FIG. 15 a side view of a tray showing material to be filtered falling onan impact area of a filter member, according to one or more embodimentsof the present disclosure.

FIG. 16A is a front-side perspective view of a screen assembly,according to one or more embodiments of the present disclosure.

FIG. 16B is a side view of a screen filter for use in an embodiment ofthe present disclosure.

FIG. 17 illustrates a flow of undersized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure.

FIG. 18 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure.

FIG. 19 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure.

FIG. 20 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure.

FIG. 21 illustrates a flow of undersized and oversized materials in ascreening assembly, according to one or more embodiments of the presentdisclosure.

FIG. 22 is a perspective top and side view of a vibratory screeningmachine, according to one or more embodiments of the present disclosure.

FIG. 23 is a perspective bottom and side view of a vibratory screeningmachine, according to one or more embodiments of the present disclosure.

FIG. 24 is a top perspective view of a combined undersized/oversizedcollecting apparatus that includes an undersized collecting assemblywith two oversized collecting troughs, according to one or moreembodiments of the present disclosure.

FIG. 25 is a bottom perspective view of the collecting apparatus of FIG.24 , according to one or more embodiments of the present disclosure.

FIG. 26 is a further top perspective view of the collecting apparatus ofFIGS. 24 and 25 , according to one or more embodiments of the presentdisclosure.

FIG. 27 is a side perspective view of the collecting the apparatus ofFIGS. 24, 25, and 26 with a plurality of installed screening deckassemblies, according to one or more embodiments of the presentdisclosure.

FIG. 28 is a further side perspective view of the collecting apparatuswith installed screening deck assemblies of FIG. 27 , according to oneor more embodiments of the present disclosure.

FIG. 29 is a further side perspective view of the collecting apparatuswith installed screening deck assemblies of FIGS. 27 and 28 , accordingto one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates generally to methods and apparatuses forscreening materials, in particular, for separating materials of varyingsizes. Embodiments of the present disclosure include screening systems,vibratory screening machines, and apparatuses for vibratory screeningmachines and screen assemblies for separating materials of varyingsizes.

Vibratory screening systems are disclosed in U.S. Pat. Nos. 6,431,366 B2and 6,820,748 B2, which are incorporated herein by reference thereto.Advantages of the present invention over previous systems include alarger screening capacity for separation of materials without anassociated increase in machine size. Embodiments of the presentinvention include improved features such as: screening deck assemblieshaving first and second screens; tensioning devices that tension eachscreen in a front to back direction (i.e., in the direction of flow ofthe material that is being screened); wash trays positioned in betweenthe first and second screens; feed chutes configured to connect directlyto an over-mounted feed system, e.g., the feed systems described in U.S.Patent App. No. 2014/0263103 A1, which is incorporated herein byreference hereto; centralized discharge assemblies which collectundersized and oversized materials; and replaceable screen assembliesconfigured for front to back tensioning and impact areas for flow ofmaterial onto the screen assemblies. These features, among othersdescribed herein, provide for a compact design that allows for a directoverhead feed system, increased screening capacity, and reducedfootprint. Additionally, the multiple screen assemblies that aretensioned front to back with wash trays in between and impact areas onthe screen assemblies themselves provide for improved flowcharacteristics and efficiencies. The improved tensioning structuresprovide for quick and easy replacement of screen assemblies. Theimproved discharge assemblies are configured for optimal or nearlyoptimal flow characteristics as well as for providing the greatlyreduced footprint. These improvements and advantages, and others, areprovided by at least some embodiments in accordance with aspects of thisdisclosure.

Example embodiments of the present disclosure employ vibratory screeningmachines to separate materials of varying sizes. In some embodiments, avibratory screening machine includes a framing assembly, a plurality ofscreening deck assemblies mounted to the framing assembly, an undersizedmaterial discharge assembly and an oversized material dischargeassembly. The framing assembly includes an inner frame mounted to anouter frame. A plurality of screening deck assemblies are mounted to theinner frame and arranged in a stacked and staggered relationship. Eachscreening deck assembly includes a first screening deck and a secondscreening deck, a wash tray extending between first and second screeningdecks, and a tensioning assembly. At least one vibrating motor may beattached to the inner frame and/or at least one screening deck assembly.An undersized material discharge assembly and an oversized materialdischarge assembly, each of which may include at least one vibratorymotor, are in communication with each screening deck assembly, and areconfigured to receive undersized and oversized screened material,respectively, from the screening deck assemblies.

In one embodiment of the present disclosure, a vibratory screeningmachine includes an outer frame, an inner frame connected to the outerframe, a vibratory motor assembly secured to the inner frame such thatit vibrates the inner frame. A plurality of screen deck assemblies isattached to the inner frame in a stacked arrangement, each configured toreceive replaceable screen assemblies. The screen assemblies are securedto the screen deck assemblies by tensioning the screen assemblies in adirection that a material to be screened flows across the screenassemblies. An undersized material discharge assembly is configured toreceive materials that pass through the screen assemblies, and anoversized material discharge assembly is configured to receive materialsthat pass over a top surface of the screen assemblies. The undersizedmaterial discharge assembly includes an undersized chute incommunication with each of the screen deck assemblies and the oversizedmaterial discharge assembly includes an oversized chute assembly incommunication with each of the screen deck assemblies.

The oversized chute assembly may include a first oversized chuteassembly and a second oversized chute assembly. The undersized chute,the first oversized chute assembly, and the second oversized chuteassembly may be located beneath the plurality of screen deck assemblies,and the undersized chute may be located between the first and secondoversized chute assemblies. At least one of the plurality of screen deckassemblies may be replaceable. Each screen deck assembly may include afirst screen assembly and a second screen assembly. A wash tray may belocated between the first screen assembly and the second screenassembly. A trough may be located between the first screen assembly andthe second screen assembly. The trough may include an Ogee-weirstructure.

The vibratory screening machine may include a screen tensioning systemthat includes tensioning rods that extend substantially orthogonal tothe direction of flow of the material being screened. The tensioningrods may be configured to mate with a portion of the screen assembly andtension the screen assembly when rotated. The screen tensioning systemmay include a ratcheting assembly configured to rotate the tensioningrod such that it moves between a first open screen assembly receivingposition to a second closed and secured screen assembly tensionedposition.

The vibratory screening machine may include a vibratory motor, whereinthe vibratory⋅motor is attached to the oversized chute assembly. Thevibratory screening machine may include multiple feed assembly units,each feed assembly unit located substantially directly below individualdischarges of a flow divider. The vibratory screening machine mayinclude at least eight screen deck assemblies.

The oversized chute assembly may include a bifurcated trough that isconfigured to receive materials that do not pass through the screenassemblies and are conveyed over a discharge end of the screen deckassemblies. A first section of the bifurcated trough may feed the firstoversized chute assembly, and a second section of the bifurcated troughmay feed the second oversized chute assembly.

In one embodiment of the present disclosure, a screen deck assemblyincludes a first screen deck configured to receive a first screenassembly, a second screen deck configured to receive a second screenassembly located downstream from the first screen deck assembly; and atrough located between the first and second screen deck assemblies,wherein the first screen deck assembly is configured to receive amaterial to be screened and the trough is configured to pool thematerial to be screened before it reaches the second screen deckassembly.

The trough may include at least one of an Ogee-weir and a wash tray. Thescreen deck assembly may include a first and a second screen tensioningsystem, each having tensioning rods that extend substantially orthogonalto the direction of flow of the material to be screened. The firsttensioning rod may be configured to mate with a first portion of thefirst screen assembly when rotated and the second tensioning rod may beconfigured to mate with a second portion of the second screen assemblywhen rotated.

The first screen tensioning system may include a first ratchetingassembly configured to rotate the first tensioning rod such that thefirst tensioning rod moves between a first open screen assemblyreceiving position to a second closed and secured screen assemblytensioned position. The second screen tensioning system may include asecond ratcheting assembly configured to rotate the second tensioningrod such that the second tensioning rod moves between a first openscreen assembly receiving position to a second closed and secured screenassembly tensioned position.

In one embodiment of the present disclosure, a method of screening amaterial includes feeding the material on a vibratory screening machinehaving a plurality of screen deck assemblies that are configured in astacked arrangement, each of the screen deck assemblies configured toreceive replaceable screen assemblies, the screen assemblies secured tothe screen deck assemblies by tensioning the screen assemblies in thedirection the material flows across the screen assemblies; and screeningthe materials such that a undersized material that passes through thescreen assemblies flows into an undersized material discharge assembly,and an oversized material flows over an end of the screen deck assemblyinto an oversized material discharge assembly. The undersized materialdischarge assembly includes an undersized chute in communication witheach of the screen deck assemblies and the oversized material dischargeassembly includes an oversized chute assembly in communication with eachof the screen deck assemblies.

The oversized chute assembly may include a first and second oversizedchute assembly. The undersized chute and first and second oversizedchute assemblies may be located beneath the plurality of screen deckassemblies, and the undersized chute may be located between the firstand second oversized chute assemblies.

At least one of the plurality of screen deck assemblies may bereplaceable. Each screen deck assembly may include a first and a secondscreen assembly. A. trough may be located between the first and secondscreen assemblies. The trough may include an Ogee-weir structure.

A screen tensioning system may be included having tensioning rods thatextend substantially orthogonal to the direction of flow of the materialbeing screened. The tensioning rods may be configured to mate with aportion of the screen assembly and tension the screen assembly whenrotated.

FIGS. 1 to 4 illustrate a vibratory screening machine 100. Vibratoryscreening machine 100 includes a framing assembly having an outer frame110, and an inner frame 120, a feed assembly 130, a plurality ofscreening deck assemblies 400, a top vibratory assembly 150, anundersized collecting assembly 160 and an oversized collecting assembly170.

FIG. 1 illustrates a side perspective view of vibratory screeningmachine 100. FIG. 2 illustrates a top perspective view of vibratoryscreening machine 100, shown from the opposite side of vibratoryscreening machine 100 as is illustrated in FIG. 1 . As is shown in FIG.2 , the opposite side of vibratory screening machine 100 includes mirrorimage components of outer frame 110 as is shown in FIG. 1 . Themirror-image outer frame components are denoted by the addition of aprime (′) at the end of the corresponding component reference number.

As is shown in FIGS. 1 and 2 , outer frame 110 includes a longitudinalset of base supports 111 and 111′, a latitudinal set of base supports112 and 112′, and two sets of upstanding channels, 113 and 113′ and 114and 114′. Upstanding channels 113 and 113′ and 114 and 114′ each havefirst ends 113A and 113′A and 114A and 114′A, mid-portions 113B and113′B and 114B and 114′B, and second ends 113C and 113′C and 114C and114′C, respectively. Each of first ends 113A and 113′A and 114A and114′A are elevated relative to second ends 113C and 113′C and 114C and114′C, with mid-portions 113B and 113′B and 114B and 114′B extending thelength between the first and second ends, respectively. Outer frame 110further includes upper angled channels 115 and 115′ and lower angledchannels 116 and 116′. Upper angled channels 115 and 115′ and lowerangled channels 116 and 116′ each have first ends 115A and 116A,mid-portions 115B and 116B, and second ends 115C and 116C, respectively.First ends 115A and 116A are elevated relative to second ends 115C and116C, and mid-portions 115B and 116B extend the length between firstends 115A and 116A and second ends 115C and 116C, respectively. Outerframe 110 also includes three sets of declining channels: 117 and 117′,118 and 118′, and 119 and 119′. Each declining channel has a first end,117A, 118A, and 119A which is elevated relative to its respective secondend, 117B, 118B, 119B.

Referring to FIGS. 1 and 2 , the opposite ends of longitudinal basesupports 111 and 111′ attach to the opposite ends of latitudinal basesupports 112 and 112′ such that the four base supports create arectangular shape. Second ends 113C and 113′C and 114C and 114′C of eachrespective upstanding channel attach to the four corners where basechannels 111 and 111′ meet base channels 112 and 112′. Mid-portion 113Band 113′B of upstanding channel 113 attaches to first end 119A ofdeclining channel 119. Second end 119B of declining channel 119 restsabove longitudinal base support 111. First end 113A of upstandingchannel 113 attaches to mid-portion 115B of upper angled channel 115 andfirst end 118A of declining channel 118. First end 115A of upper angledchannel 115 attaches to first end 117A of declining channel 117. Secondend 117B of declining channels 117 attaches to mid-portion 116B of lowerangled channel 116 towards first end 116A. Second end 118B of decliningchannel 118 attaches to mid-portion 116B of lower angled channel 116toward second end 116C. Second end 116C of lower angled channel 116attaches to and terminates at second end 119B of declining channel 119.

Referring to FIG. 2 , outer frame 110 further includes a rear channel109 having opposite ends that attach to one of each of mid-portions 113Band 113B′ of upstanding channel 113. Additional rear channels 108 runparallel to rear channel 109, each with opposite end attached to lowerangled channel 116 and its counterpart lower angled channel 116′ frommid-portion 116B toward second end 116C to provide structural support toouter frame 110.

As is shown in FIG. 2 , inner frame 120 mounts top vibratory assembly150 and screening deck assemblies 400 via securing mechanisms, such asbolts. Inner frame 120 includes upper angled channels 125 and 125′,lower angled channels 126 and 126′, upper declining channels 127 and127′, and lower declining channels 128 and 128′. Upper and lower angledchannels 125 and 126 of inner frame 120 run parallel to upper and lowerangled channels 115 and 116 on the medial side of outer frame 110. Upperand lower declining channels 127 and 128 of inner frame 120 run parallelto declining channels 117 and 118 on the medial side of outer frame 110.Though not shown in FIGS. 1 and 2 , inner frame 120 may be mounted toouter frame 110 with elastomeric mountings, or other similar mountings,which permit inner frame 120 to maintain vibratory motion whiledampening the effects of vibration on the structural integrity of fixedouter frame 110. In an embodiment, elastomeric mountings are made of acomposite material including rubber and have female threads that acceptmale bolts from the inner frame and outer frame. The elastomericmountings may be replaceable parts. While outer frame 110 is shown inthe specific configuration described, it may have differentconfigurations as long as it provides the structural support necessaryfor inner frame 120. In embodiments, vibratory screening machine 100 mayhave an outer frame that includes feet that are configured to attach toan existing structure.

In some embodiments, top vibratory assembly 150 includes side plates 153and 153′, a first vibrating motor 151A and a second vibrating motor151B. Side plates 153 and 153′ have a top angled edge 154, a bottom edge155, and an exterior surface 156. Bottom edge 155 of side plate 153 issecured to a side channel 430 of screening deck assembly 400 viasecuring mechanisms, such as bolts. Exterior surface 156 includes ribs157 that provide structural support to top vibratory assembly 150. Theopposing sides of vibrating motor 151A and second vibrating motor 151Bare mounted to top angled edges 154 of side plates 153 and 153′. Firstand second vibrating motors 151A and 151B are configured such that theymay vibrate all screening deck assemblies 400 mounted to inner frame120. While shown with a particular configuration in FIGS. 1 and 2 , itis noted that top vibratory assembly 150 may have other arrangementsthat retain the functionality described herein.

As is shown in FIG. 2 , vibratory screening machine 100 includes a feedassembly 130. Feed assembly 130 includes support frame 134, a pluralityof vertical supports 136, feed inlet ducts 131, mounting arms 132, andfeed outlet ducts 133. Mounting arms 132 are secured to support frame134 and 134′ with securing mechanisms, such as bolts. Support frame 134and 134′ is located above and parallel to declining channels 117 and117′ of outer frame 110. Vertical supports 136 secure support frame 134and 134′ to declining channels 117 and 117′ of outer frame 110 such thatfeed assembly 130 is fixed relative to vibrating inner frame 120. Inletducts 131 are configured to receive a flow of slurry from a flow dividerdevice, such as shown in U.S. Patent Application No. 2014/0263103 A1,which is incorporated herein by reference in its entirety, or othermaterial flow assemblies, and feed it to outlet ducts 133. Outlet ducts133 are positioned above elevated sides of screening deck assemblies 400such that each outlet duct 133 is configured to discharge a flow ofmaterials 500 to each screening deck assembly 400. Earlier systems havehoses located a story above vibratory machines, whereas in assemblies ofthis disclosure, configurations of inlets on the vibratory machineprovide for substantially distributed drops in flow and greatly reducethe height of the machine. This is an important space saving feature ofat least some embodiments of the present disclosure.

FIG. 3 illustrates a front view of the vibratory screening machine 100.FIG. 4 illustrates a rear view of the vibratory screening machine 100.As is shown in FIGS. 3 and 4 , the vibratory screening machine 100includes an undersized material collection assembly 160 and an oversizedmaterial collection assembly 170. Referring to FIG. 3 , undersizedmaterial collection assembly 160 includes a plurality of collecting pans161 secured to the underside of each screening deck assembly 400, aplurality of ducts 162 in communication with collecting pans 161, and anundersized collecting chute 166. Oversized material collection assembly170 includes a plurality of oversized collecting chutes 171 mounted tolower end plate 428 of each screening deck assembly 400, and twooversized collecting troughs 176 and 176′ in communication withoversized collecting chutes 171. As is shown in FIG. 4 , oversizedcollecting troughs 176 and 176′ include vibratory motors 179 and 179′.As is shown in FIGS. 3 and 4 , undersized collecting chute 166 extendsbetween oversized collecting chute 171 and oversized collecting troughs176 and 176′ beneath screening deck assemblies 400 of vibratoryscreening machine 100. Though shown in a specific configuration,oversized collecting troughs 176 and 176′ and vibratory motors 179 and179′ may have different arrangements so long as they aid in conveyingoversized material 500 discharged from screening deck assemblies acrossoversized collecting troughs 176 and 176′.

FIGS. 5 to 10 illustrate various views of a screening deck 400. FIG. 5illustrates an enlarged isometric perspective view of screen assembly400. Screening deck assembly 400 includes a first screening deck 410, asecond screening deck 420, side channels 430 and 430′, a wash tray 440,and a tensioning device 450. As is shown in FIG. 5 , first screeningdeck 410 and second screening deck 420 are covered by a first screenassembly 409 and a second screen assembly 419, respectively. Firstscreen assembly 409 and second screen assembly 419 are replaceablescreen assemblies which are attached to first and second screening decks410 and 420. When in operation, material to be screened 500 by vibratoryscreening machine 100 is discharged from feed outlet ducts 133 of feedassembly 130 to the elevated side of first screen assembly 409, alongfeed end 409A of first screen assembly 409, and is vibrated across firstscreen assembly 409 of first screening deck 410, over discharge end 409Bof first screen assembly 409, and into wash tray 440. Vibration carriesmaterial 500 over wash tray 440, where material passes over feed end419A of second screen assembly 419. As is described herein, material 500hits second screen assembly 419 in screen impact area 448, then vibratesacross second screen assembly 419 of second screening deck 420, and overdischarge end 419B of second screen assembly 419 along lower end plate428. First screen assembly 409 and second screen assembly 419 areconfigured such that undersized materials fall through first screenassembly 409 and second screen 419 into undersized material collectingpans 161, and are funneled into undersized collecting chute 166 viaducts 162. Oversized materials do not pass through screens 409 and 419and are vibrated off lower end plate 428 and funneled through oversizedcollecting chutes 171 and 171′ to oversized collecting troughs 176 and176′. Direction of the flow of material is represented with largearrows. While illustrated in this particular configuration in thefigures, oversized collecting chutes 171 and 171′ and oversizedcollecting troughs 176 and 176′ may have different arrangements so longas they receive oversized materials discharged from each screening deckassembly and provide functionality as described herein. The flow ofmaterial through split outside oversized collecting chutes 171, 171′ anda central undistributed undersized collecting chute 166 provides forefficient flows in reduced space. The configuration of the chutes 166,171, 171′ reduces the footprint of the machine 100 while providing fordirect and efficient flow.

First screening deck 410 includes an upper end plate 416 and a lower endplate 418. Second screening deck 420 includes an upper end plate 426 anda lower end plate 428. Opposite sides of first screening deck 410 andsecond screening deck 420 are secured to the medial sides of sidechannels 430 and 430′ with securing mechanisms such as, e.g., bolts orwelding. The lateral sides of side channels 430 and 430′ include aplurality of angled plates 432. Angled plates 432 include holes throughwhich securing mechanisms, such as bolts, may extend to secure sidechannels 430 and 430′ to upper declining channel 127 and 127′ and lowerdeclining channel 128 and 128′ of inner frame 120. While illustrated inthis particular arrangement, side channels 430 and 430′ and angledplates 432 may have different configurations so long as they permitscreening deck assembly 400 to vibrate such that materials 500 ofvarying sizes are separated as desired.

FIG. 6 illustrates a partial side perspective view of screening decks410 and 420, wash tray 440, side channel 430, and a portion oftensioning device 450. As is shown in FIG. 6 , a flexible material 405covers outlet duct 133 of feed assembly 130. Flexible material 405 isconfigured to control the flow of materials from outlet duct 133 toscreening deck assembly 400 so that the flow of material is uniformlydistributed across screening deck assembly 400, thereby maximizingefficiency of vibratory screening machine 100. As is shown in FIG. 6 ,first screening deck 410 and second screening deck 420 do not includescreens 409 and 419, but it will be appreciated that first and secondscreening decks 410 and 420 are covered by screens 409 and 419 whenvibratory screening machine 100 is employed to separate materials ofvarying sizes, and can be changed out, as described herein, when worn ordamaged. Referring to FIG. 6 , first screening deck 410 includes a rib412, stringers 414, an upper end plate 416 and a lower end plate 418.Second screening deck 420 includes a rib 422, stringers 424, an upperend plate 426 and a lower end plate 428. Opposite ends of ribs 412 and422 extend from side channel 430 and 430′ at each of the midpointsbetween upper end plate 416 and lower end plate 418 of first screeningdeck 410, and upper end plate 426 and lower end plate 428 of secondscreening deck 420, respectively. A plurality of stringers 414 and 424extend from upper end plates 416 and 426 to lower endplates 418 and 428,respectively. A midpoint 415 of each stringer 414 and a midpoint 425 ofeach stringer 424 traverses the top surface of ribs 412 and 422.Midpoints 415 and 425 are elevated with respect to opposite ends ofstringers 414 and 424 such that stringers 414 and 424 create a “crown”or curvature across first and second screening decks 410 and 420. Thoughfirst screening deck 410 and second screening deck 420 are shown with asingle rib 412 and 422 respectively, it will be appreciated that firstscreening deck 410 and second screening deck 420 may include otherconfigurations. First screening deck 410 and second screening deck 420may include, respectively, a first plurality of ribs and a secondplurality of ribs, so long as the additional ribs provide thefunctionality as described herein. In some embodiments at least one (or,in some embodiments, each one) of the first plurality of ribs and thesecond plurality of ribs can be assembled similarly to rib 412 or rib422.

Distinct from screening assemblies of other systems, such as thosedisclosed in U.S. Pat. No. 6,431,366, stringers 414 and 424 may bereplaceable units, and may be bolted to ribs 412 and 422 rather thanwelded to ribs 412 and 422. This configuration eliminates closely spacedweld joints between ribs 412 and 422 and stringers 414 and 424 that arecommonly found in welded screening decks. This arrangement eliminatesthe shrink, heat distortion and drop associated with closely spaced weldjoints, and enables rapid replacement of worn or damaged stringers 414and 424 in the field. Replaceable stringers 414 and 424 may includeplastic, metal, and/or composite materials and may be constructed bycasting and/or injection molding. While not shown in FIG. 6 , screeningdecks 410 and 420 are configured to support screens 409 and 419, whichextend across the surface of first screening deck 410 and secondscreening deck 420, covering ribs 412 and 422 and stringers 414 and 424,respectively, as is shown in FIG. 5 .

With further reference to FIG. 6 , upper end plate 416 of firstscreening deck 410 is elevated relative to lower end plate 418.Similarly, upper end plate 426 of second screening deck 420 is elevatedrelative to lower end plate 428. Wash tray 440 extends between lowerendplate 418 of first screening deck 410 and upper endplate 426 ofsecond screening deck 420. First screening deck 410, wash tray 440, andsecond screening deck 420 are configured such that a flow of materialfrom outlet duct 133 and flexible material 405 of feed assembly 130traverses first screening deck 410 and wash tray 440 before traversingsecond screening deck 420. This configuration enables a flow ofmaterials to be effectively separated by increasing the surface area onwhich the flow of materials is screened into oversized materialcollecting assembly 170 and undersized material collecting assembly 160without increasing the footprint of vibratory screening machine 100.

FIG. 7 illustrates an isometric side view of wash tray 440 interfacingwith first screening deck 410 and second screening deck 420. As is shownin FIG. 7 , wash tray 440 includes an upper side member 442 having a topportion 442A and a bottom portion 442B, a lower member 444 having afirst end 444A and a second end 444B, and a curved side member 446including a first end 446A and a second end 446B. Curved side member 446includes an S-shape curve referred to as an “Ogee,” discussed in moredetail below. Top portion 442A of upper side member 442 connects tolower end plate 418 of first screening deck 410. Bottom portion 442B ofupper side member 442 connects to first end 444A of lower member 444.Second end 444B of lower member 444 connects to first end 446A of curvedside member 446. Second end 446B of curved side member 446 curves overupper end plate 426 of second screening deck 420.

The resulting configuration of wash tray 440 generates a weir 447, whichis a trough or depression that provides a structure for pooling a flowof liquid or slurry material to be screened 500. Embodiments of a washtray 440 having an Ogee-weir structure possess functional significancein the field of fluid dynamics. An Ogee-weir structure is generallydescribed as slightly rising up from the base of a weir and reaching amaximum rise 449 at the top of the S-shaped curve of the Ogee structure.Upon or after reaching maximum rise point 449, fluid falls over the Ogeestructure in a parabolic form. The discharge equation for an Ogee-weiris:

$Q = {\frac{2}{3}C_{d} \times L\sqrt{2{g(H)}^{\frac{3}{2}}}}$

As is shown in FIG. 7 , incorporating wash tray 440 with an Ogee-weircurved side member 446 between first screening deck 410 and secondscreening deck 420 of screening deck assembly 400 may direct the flow ofmaterial screened by first screening deck 410 onto a desired impactpoint or impact area 448 near upper end plate 426 of second screeningdeck 420, or another desired location, such that the discharge flowimpacts the downstream screen panel at a predetermined wear surface asopposed to non-uniformly impacting downstream screen surfaces such asthe screen openings. In this configuration, impact point/area 448 mayremain unchanged despite changes in fluid parameters such as, e.g.,flowrate and/or viscosity. Incorporation of Ogee-weir shaped curved sidemember 446 into wash tray 440 improves screening efficiency andconsistency and reduces wear on second screening deck 420. Flows ofmaterials after impact are represented with large arrows in FIG. 7 .

FIGS. 8, 9A and 9B illustrate tensioning device 450. FIG. 8 illustratesan isometric perspective view of tensioning device 450. Tensioningdevice 450 includes a tensioning rod 451, brackets 454 and 454′, andratchet mechanisms 456 and 456′. FIG. 9A illustrates a partial side viewof two ratchet mechanisms 456 and two brackets 454 mounted to sidechannel 430 of screening deck assembly 400. FIG. 9B illustrates anenlarged view of one of two ratchet mechanisms 456 and brackets 454shown in FIG. 9A. As described in more detail below, each screening deckassembly 400 includes two tensioning devices 450, one configured toenable tensioning of screen assembly 409 of first screening deck 410,and the other configured to enable tensioning of screen 419 of secondscreening deck 420.

Referring to FIG. 8 , tensioning device 450 includes a tensioning rod451, brackets 454 and 454′, and ratchet mechanisms 456 and 456′.Tensioning rod 451 includes opposing, mirror image ends 452 and 452,′ atubular midportion 453, and a tensioning strip 455. Opposing ends 452and 452′ of tensioning rod 451 extend through holes 457 and 457′ inratchet mechanisms 456 and 456′, respectively, and are secured toratchet mechanisms 456 and 456′ by securing mechanisms, such as bolts.Ratchet mechanisms 456 and 456′ are secured to brackets 454 and 454′,which are in turn secured to side channels 430 and 430′, respectively,of screening deck assembly 400, by securing mechanisms, such as bolts,as is shown in FIGS. 9A and 9B.

While not shown in FIG. 8 , tubular mid-portion 453 of tensioning rod451 extends the width of screening deck assembly 400 from side channel430 to side channel 430′. Tensioning rods 451 of each tensioning device450 are located beneath upper end plate 416 of first screening deck 410and upper end plate 426 of second screening deck 420. Tubularmid-portion 453 and tensioning strip 455 of tensioning device 450 areconfigured to receive an end of screen assembly 409 and/or 419. Opposingend 452, tubular mid-portion 453, and tensioning strip 455 of tensioningrod 451 are arranged so that when opposing end 452 and tubularmid-portion 453 rotate in a counter-clockwise direction, tensioningstrip 455 rotates in a clockwise direction, thereby pulling screenassembly 409 and/or 419 towards upper end plate 416 of first screeningdeck 410 and/or upper end plate 426 of second screening deck 420. Whileshown in FIG. 8 as having tubular mid-portion 453 and tensioning strip455, tensioning device 450 may include other components so long as it isconfigured receive an end of screen assembly 409 and/or 419 and isconnected to ratchet mechanism 456 so as to permit ratchet mechanism 456to rotate tensioning rod 451 and pull screen assembly 409 and/or 419toward upper end plates 416 and/or 426.

FIG. 9A illustrates a partial side view of two ratchet mechanisms 456and two brackets 454 of two tensioning devices 450 mounted to sidechannel 430 of screening deck assembly 400. FIG. 9B illustrates anenlarged view of ratchet mechanism 456 and bracket 454. Though notshown, tensioning rods 451 extend from each ratchet mechanism 456 onside channel 430 of screening deck assembly 400 to each ratchetmechanism 456′ on opposing side channel 430′ beneath upper end plates416 and 426 of screening deck assembly 400.

FIG. 10 illustrates an enlarged partial perspective view of ratchetmechanism 456 mounted to side channel 430 below first screening deck410. First screening deck 410 is shown interfacing with feed assembly130 and flexible flow controlling material 405. As is shown in FIG. 10 ,ratchet mechanism 456 includes an upper portion 458 and a lower portion460. Upper portion 458 includes a locking bar 459 that interfaces with amultitude of teeth 461 on lower portion 460. Lower portion 460 includesan actuation point 462 where second end 452 of tensioning rod 451extends through hole 457 of ratchet mechanism 456. Referring to FIG. 10, a wrench 463 is configured to rotate actuation point 462 of ratchetmechanism 456. In response to application of a counter-clockwiserotational force to wrench 463, actuation point 462 and tubularmid-portion 453 of tensioning rod 451 are configured to rotate in acounter-clockwise direction, and tensioning strip 455 is configured torotate in a clockwise direction such that tensioning device 450 pulls anend of screen assembly 409 toward upper end plate 416. In response torotation of wrench 463 and actuation point 462 of ratchet mechanism 456,locking bar 459 of upper portion 458 and teeth 461 of lower portion 460are configured to lock the tensioning device in place and retaintension. Whereas tensioning devices used in vibratory screening machinesdisclosed in the prior art apply tension in a side-to-side direction, ortowards side channels 430 and 430′ relative to vibratory screeningmachine 100, tensioning device 450 disclosed herein applies tension in afront-to-back direction, or towards upper end plate 416 and lower endplate 418 of first screening deck 410 and/or upper end plate 426 andlower end plate 428 of second screening deck 420 relative to vibratoryscreening machine 100. Unlike tensioning devices disclosed in the priorart, the front-to-back direction of tensioning provided by tensioningdevice 450 corresponds with the direction of the flow of material suchas, e.g., slurry, across first and second screening decks as it isseparated by vibratory screening machine 100. Though shown with wrench463 in FIG. 10 , other tools may be employed to rotate actuation point462 of ratchet mechanism 456, so long as it provides functionality asdescribed herein.

FIGS. 11A and 11B illustrate an embodiment of undersized materialcollection assembly 160. Undersized material collection assembly 160includes a plurality of collecting pans 161 secured to the underside ofeach screening deck assembly 400 (see FIGS. 3 and 4 ), a plurality ofducts 162 in communication with collecting pans 161, and an undersizedcollecting chute 166. As is shown in FIGS. 11A and 11B, undersizedcollecting chute 166 includes a mounting end 167, which may be securedto outer frame 110 of vibratory screening machine 100 by securingmechanisms, such as bolts, a top surface 168 that runs the length ofcollecting chute 166, and a discharge port 169. Each duct 162 includesan inlet 163, a chamber 164, and an outlet 165. Inlet 163 of each duct162 is configured to receive undersized material from collecting pans161 and funnel the material through chamber 164 of duct 162 to outlet165. Each outlet 165 communicates with a portion of top surface 168 ofundersized collecting chute 166 such that material discharged fromoutlets 165 of ducts 162 enters collecting chute 166 and exits throughdischarge port 169. An undersized material hopper may be configured toreceive undersized material discharged from discharge port 169. Thoughnot shown, inlets 163 of ducts 162 may include radial clearances toaccommodate vibratory motion from collecting pans 161 (see FIGS. 3 and 4), which are mounted to screening deck assemblies 400, whereas ducts 162and collecting chute 166 are mounted to fixed outer frame 110. Theplacement of the undersized collecting chutes directly beneath ducts 162increases the efficiency of vibratory screening machine 100 and savesspace by centralizing the flow of all undersized material into a centralchannel.

FIGS. 12A and 12B to FIGS. 13A and 13B illustrate oversized materialcollection assembly 170. Oversized material collection assembly 170includes a plurality of oversized collecting chutes 171 mounted to lowerend plate 428 of each screening deck assembly 400, and two oversizedcollecting troughs 176 and 176′ in communication with oversizedcollecting chutes 171 (see FIGS. 3 and 4 , for example).

FIGS. 12A and 12B illustrate an embodiment of oversized collecting chute171. FIGS. 13A and 13B illustrate an embodiment of oversized collectingtrough 176. Referring to FIGS. 12A & 12B, each oversized collectingchute 171 includes a first side 172 and a second side 172′ mirroringfirst side 172, both having an inlet 173 with a mounting arm 173A, achamber 174, and an outlet 175. Mounting arms 173A of each oversizedcollecting chute 171 are secured to each lower endplate 428 of screeningdeck assemblies 400 with securing mechanisms, such as bolts, such thatmaterial that does not pass through screens 409 and/or 419 to undersizeddischarge assembly rolls off lower endplate 428 of screening deckassemblies 400 into inlet 173 of oversized material collecting chute 171(see FIGS. 3 to 4 , for example). Upon or after entry into inlet 173,oversized material is funneled through chamber 174, and discharged fromoutlet 175 into oversized collecting trough 176. While shown having atrapezoidal shape, it will be appreciated that oversized collectingchute 171 is not limited to this configuration. Oversized collectingchute 171 may have other arrangements, so long as such a chute canreceive oversized material from lower endplate 428 of screening deckassemblies 400 and can transfer oversized material to one of oversizedcollecting troughs 176 and 176′.

Referring to FIGS. 13A and 13B, oversized collecting trough 176 includesa mounting end plate 177, a back surface 178, an outlet 180, and achannel 181. Mounting end plate 177 is secured to rear channel 129 ofinner frame 120 with securing mechanisms, such as bolts (see FIGS. 3 and4 , for example). Channel 181 extends from mounting end plate 177 tooutlet 180 beneath each outlet 175 of oversized collecting chutes 171such that oversized material discharged from each of oversizedcollecting chutes 171 falls into channel 181 of oversized collectingtrough 176. A vibratory motor 179 is mounted to back surface 178 ofoversized collecting trough 176 with securing mechanisms, such as bolts,to increase the rate at which oversized material passes through channel181 to outlet 180, thus increasing the volume of material that vibratoryscreening machine 100 may process overall. Though not shown, anoversized material hopper may be configured to receive oversizedmaterials discharged from outlet 180 of oversized collecting trough 176.

FIG. 14 is a side view similar to FIG. 7 of screening deck assembly 400showing details of tensioning assembly 450 tensioning second screen 419along second screening deck 420. As indicated in FIG. 14 , material tobe screened 500 flows via vibration across first screen assembly 409toward discharge end 409B of first screen assembly 409. During passage,appropriately sized particles of material 500 pass through openings orpores 488A of first screen assembly 409. After passing over thedischarge end 409B of first screen assembly 409B, material 500 passesinto wash tray 440 and over curved side member 446 and maximum rise 449.After passing over maximum rise 449, the material 500 lands on an impactarea 448 of second tray 419, and then vibrates across second screen 419,passing from input end 419A to discharge end 419B, with appropriatelysized particles of material 500 passing through second screen 419 alongthe way. Screens 409, 419 are selectively affixed to decks 410, 420 viadeck clips 455B of the decks 410, 420 and tensioning strips 455 of thetensioning devices 450, in a manner described in greater detail below.

As it can be understood from FIG. 14 and as is explained in furtherdetail below, a discharge end 409B, 419B of screen assemblies 409, 419is attached to a fixed deck clip 455B, while an opposing input end 409A,419A is attached to a tensioning strip 455 of tensioning device 450.When tensioning strip 455 is rotated, the screen assembly 409, 419 istensioned front-to-back across the associated deck 410, 420, in the samedirection that material to be screened flows across the screen deckassembly 400. This is an improvement over earlier systems, where screenassemblies were tensioned from the sides, leaving a crown that wasperpendicular to the flow of the material to be screened, creatingvalleys and inefficiencies in flows.

FIG. 15 is a side perspective view of a screening deck assembly 400showing additional details of first and second screen assemblies 409,419 tensioned over first and second screening decks 410, 420,respectively. In FIG. 15 , portions of screens 409, 419 have beencutaway to show aspects of decks 410, 420 below the screens. Material500 is shown passing over wash tray 440 and crashing onto impact area448 of second filter 419.

FIGS. 16A and 16B show views of a screen assembly 419 for use with thevibratory screening machine 100 and screening deck assembly 400described above. While the following description of embodiments depictedin FIGS. 16A and 16B is made with reference to second screen assembly419, it is noted that this discussion applies equally to first screenassembly 409; first screen assembly 409 can typically be identical toscreen assembly 419, but optionally may have different sizes andconfigurations, e.g. different sized impact area 448 (smaller orlarger), different size opening configurations, a combination thereof,or the like.

FIG. 16A is a front-side perspective view of screen 419 in accordancewith one or more embodiments of the disclosure. Screen 419 is configuredfor removably securing to deck 420 under tension in the manner describedherein. Screen 419 includes feed end 419A and opposing discharge end419B. Screen 419 has a widthwise dimension between ends 419A and 419B,and a lengthwise dimension between opposing side edges 483. A filterarea 488 is defined by a plurality of individual openings or pores 488Aextending substantially across the surface of the screen 419. Theopenings 488A are of a selected size, such as a size determined by sidelengths having respective magnitudes in a range from about 20 micronsand about 100 microns. In some embodiments, the openings 488A can berectangular shaped and can have a substantially uniform width orsubstantially uniform thickness in a range between about 43 microns toabout 100 microns, and a substantially uniform length in a range betweenabout 43 microns to about 2000 microns.

In the embodiment of FIG. 16A, the filter area 488 is framed by animpact zone 448 formed along feed end 419A, a strip 486 along dischargeend 419B, and opposing side strips 484 along respective side edges 483.Ends of the impact zone 448, strip 486, and side strips 484 integrallyjoin together at abutment points, and together provide structuralsupport to the filter area 488, preventing tearing and the like duringplacement and use on the machine 100. With reference to FIG. 14 , asmaterial 500 flows over the curved member 446 of the wash tray 440, thematerial 500 lands on impact zone 448. Impact zone 448 protects theintegrity of the individual openings 488A and prevents or decreases thelikelihood of large particles becoming lodged in the openings 488A. Asindicated in FIG. 14 , as material 500 flows from feed end 419A todischarge end 419B, appropriately sized particles of material 500 passthrough openings 488A. Impact zone 448 may have different sizes andconfigurations depending on the screening application and desired flowcharacteristics.

As is shown in FIGS. 16A and 16B, a first binder strip 481A is providedalong feed end 419A, while a second binder strip 481B is provided alongdischarge end 419B. Each binder strip 481A, 481B may be a generallyU-shaped strip of metal that is integrated into feed ends 419A, 419B,substantially along the length of each respective end 419A, 419B. Whilealternative means may be used to attach binder strips 481A, 481B toscreen 419, the binder strips 481A, 481B are configured to withstandsubstantial forces during operation of the vibratory screening machine100 without separating from screen 419 or otherwise allowing screen 419to come loose from deck 420.

FIG. 16B is a side view of a screen filter 419 for use in an exemplaryembodiment of the present disclosure. When viewed from the side as inFIG. 16B, screen 419 presents a thin profile. As seen in FIG. 16B, thescreen filter 419 includes a material input surface 485A on an upperside, and a material output surface 485B on an opposing lower sidethereof. Individual screen openings 488A extend from input side 485A tooutput side 485B, such that during vibratory screening, individualparticles pass through the screen area 488. In the embodiment depictedin FIG. 16B, first and second binder strips 481A, 481B depend downwardfrom the lower side of screen 419. Each binder strip 481A, 481B curvesback toward a center of screen 419, such as in an L-shape or C-shape.

The screen assembly 409, 419 is dimensioned to match the size of deck410, 420. In some embodiments, screen assembly 409, 419 preferably has alength of about 56 cm, a width of about 30 cm, and a thickness of about0.25 cm. Impact area 448 is about 3 cm wide; narrower or wider impactareas 448 can be used, with the former decreasing protection and thelatter decreasing the number of openings 488A. Strip 486 and side strips484 are about 1 cm wide. The screens 409, 419 are preferably made ofpolyurethane. While exemplary embodiments of screens 419 are depicted inFIG. 16A and FIG. 16B for use with the vibratory screening machine 100described herein, it will be appreciated that the machine 100 can beconfigured for use with alternative configuration of screens, screenmaterials, and screen characteristics (opening/pore size, connectionmechanisms, and the like). Examples of screens, screen materials andscreen characteristics that can be incorporated into screens 409, 419for use with machine 100 are found in applicant's U.S. Pat. No.9,409,209, U.S. Patent Application Publication 2013/313,168A1, U.S.Patent Application Publication 2014/0262978A1, and U.S. PatentApplication Publication 2016/0310994A1, the disclosures of which areincorporated herein by reference in their entirety.

A method of attaching a screen assembly 409, 419 to a deck 410 420 willnow be described. As is seen in FIG. 14 , deck clips 455B are fixedadjacent to respective output ends 410B, 420B of decks 410, 420. Deckclips 455B are sized and configured for attaching output ends 409B, 419Bof screens 409, 419 to screening decks 410, 420. In an embodiment, deckclips 455B extend substantially along a length of discharge end 410B,420B, in a manner analogous to binder strips 481A, 481B extending alonglengths of screen assembly 409, 419. In FIG. 14 , deck clip has anL-shaped aspect when viewed in side profile, although other engagementconfigurations, such as curved C-shaped aspects, can be used. As can beunderstood from FIG. 14 , second binder strip 481B along discharge end409B, 419B of a screen assembly 409, 419 is engaged to deck clip 455B,such that the L- or C-shaped aspect of binder strip 481B interdigitateswith L- or C-shaped aspect of deck clip 455B. Tension is applied tospread screen assembly 409, 419 across the deck 410, 420 toward inputend 410A, 420A, such that binder clip 481B remains interconnected withdeck clip 455B. With screen assembly 409, 419 spread across deck 410,420, first binder strip 481A of screen assembly 409, 419 is then engagedto tensioning strip 455 of tensioning device 450, such that an L- orC-shaped aspect of tensioning strip 455 interconnects with first binderstrip 481A. Tension is then applied to screen assembly 409, 419 viatensioning device 450 to thereby selectively lock first binder strip481A to tensioning strip 455, whereby filter 409, 419 is tensionedtightly along deck 410, 420 for use in screening particles of material500 during operation of the machine 100.

After a period of use, screens 409, 419 can be selectively removed fromdeck 410, 420 for replacement with new screens 409, 419. In a method ofscreen removal, tensioning device 450 is used to release tension strip455 from first strip 481A. Screen assembly 409, 419 is then pulled orslid toward discharge end 410A, 420A of deck 410, 420 to release secondbinder strip 481B from deck clip 455B.

FIG. 17 illustrates a flow of undersized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure. In this example, a screen deck assembly 400 includes ascreen 409 and an undersized material collection assembly 160.Undersized material collection assembly 160 includes a collecting pan161 which collects fluid and undersized materials that flow through ascreen surface of screen 409. Undersized material collection assembly160 is configured to allow fluids and undersized materials to leavescreen deck assembly 400 and to flow into an inlet 163 of ducts 162 ofan undersized collection chute 166.

FIG. 18 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure. In this example, an oversized material collection assembly170 includes an oversized collecting chute 171 that is mounted to lowerend plate 428 of screening deck assembly 400. Oversized materialcollection assembly 170 further includes two oversized collectingtroughs 176 and 176′ in communication with oversized collecting chute171. As shown, oversized material that does not flow through the screensurface of screen 409 is collected by oversized collecting chute 171 andfed to collecting troughs 176 and 176′.

FIG. 19 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure. In this example, oversize material collection assembly 170does not have oversized collecting chute 171 (e.g., see FIG. 18 ).Rather, in this embodiment, a deflector 1902 causes oversized materialthat does not pass through the surface of screen 409 to flow pastdeflector 1902 to thereby be guided to collecting troughs 176 and 176′.In this example, deflector 1902 may be a triangular deflector that isconfigured to reside on the surface of screen 409.

FIG. 20 illustrates a flow of oversized materials in a screeningassembly, according to one or more embodiments of the presentdisclosure. This example shows an alternative embodiment to thatdescribed above with reference to FIG. 19 . In this example, thetriangular shaped deflector 1902 of FIG. 19 has been replaced, in thisembodiment, by a wedge-shaped deflector 2002. In other embodiments, manyother configurations of deflectors may be employed, including defectorsthat are external to screen deck assembly 400.

FIG. 21 illustrates a flow of undersized and oversized materials in ascreening assembly, according to one or more embodiments of the presentdisclosure. In this example, undersized collecting chute 166 (e.g., seeFIG. 17 ) and oversized collecting troughs 176 and 176′ (e.g., see FIGS.18 to 20 ) have been replaced by a single structure 2100 that has first2102, second 2104 a, and third 2104 a channels. First channel 2102 isconfigured to collect fluids and undersized materials from collectingpan 161 that flow through the surface of screen 409. Second 2104 a andthird 2104 b channels are configured to collect oversized materials thatdo not flow through the surface of screen 409. This embodiment is shownhaving deflector 1902. Other embodiments, however, may include otherdeflector structures, such as deflector 2002 (e.g., see FIG. 20 ) or mayinclude an oversized collecting chute 171 (e.g., see FIG. 18 ). Forsimplicity, FIG. 21 is shown in a geometry in which screen deck assembly400 makes a shallow angle 2107 relative to structure 2100. In practice,angle 2106 is larger to thereby accommodate a plurality of screen deckassemblies 400, as shown above in other examples, and in examplesillustrated in FIGS. 27 to 29 .

FIG. 22 is a perspective top and side view of a vibratory screeningmachine 2200, according to one or more embodiments of the presentdisclosure. Vibratory screening machine 2200 has many of the samefeatures as vibratory screening machine 100, described above withreference to FIGS. 1 to 4 . In this embodiment, however, undersizedcollecting chute 166 and oversized collecting troughs 176 and 176′, havebeen replaced by the single structure 2100. As described above, withreference to FIG. 21 , structure 2100 has first 2102, second 2104 a, andthird 2104 a channels as shown in further detail in FIG. 23 .

FIG. 23 is a perspective bottom and side view of vibratory screeningmachine 2200, according to one or more embodiments of the presentdisclosure. As described above, structure 2100 has first 2102, second2104 a, and third 2104 a channels. First channel 2102 collectsundersized materials, while second 2104 a and third 2104 a channelscollect oversized materials. Undersized and oversized materials may beremoved from vibratory screening machine 2200 through first 2102, second2104 a, and third 2104 b channels as described above in otherembodiments.

FIG. 24 is a top perspective view of a combined undersized/oversizedcollecting apparatus 2400 that includes an undersized collectingassembly 2402 with two oversized collecting troughs (only one trough2404 a visible in this view), according to one or more embodiments ofthe present disclosure. Undersized collecting assembly 2402 includes aplurality of ducts 2406 in communication with a collecting pan 2408.Undersized collecting assembly 2402 has a similar structure toundersized collecting assembly 160, and performs a similar function toundersized collecting assembly 160, as described above with reference toFIGS. 11A and 11B. Similarly, oversize collecting troughs 2404 a and2404 b (e.g., see FIG. 26 ) each have a similar structure to, andperform a function similar to, oversized collecting troughs 176 and 176′described above with reference to FIGS. 4, 13A, and 13B.

Collecting apparatus 2400 of FIG. 24 collects oversized and undersizedmaterials and functions similarly to systems described above withreference to FIGS. 11A to 13B. Collection apparatus 2400, however,eliminates the need for oversized collecting chutes 171, described abovewith reference to FIGS. 12A and 12B. In this regard, undersizedcollecting assembly 2402 further includes an angled surface 2410(described in greater detail below with reference to FIG. 26 ) thatdiverts oversize materials flowing over end plate 428 of screening deckassembly 400 (e.g., see FIG. 5 ) into oversize collecting trough 2404 a(and oversize collecting trough 2404 b shown in FIG. 26 ). In thisregard, angled surface 2410 plays a role that is similar to the roleplayed by oversized collecting chutes 171 in previously-describedembodiments. Further, the presence of angled surface 2410 eliminates theneed for deflectors 1902, described above with reference to FIGS. 19 and21 , and deflector 2002, described above with reference to FIG. 20 .Collecting apparatus 2400 further includes a plurality of divertingstructures 2412 that act to guide oversized materials toward oversizedcollecting troughs 2404 a and 2404 b (e.g., see FIG. 26 ) and away fromducts 2406. Collecting apparatus 2400 may further include splash guards2414.

FIG. 25 is a bottom perspective view of collecting apparatus 2400 ofFIG. 24 , according to one or more embodiments of the presentdisclosure. In this view, both oversized troughs 2404 a and 2404 b maybe seen. Further, oversized trough 2404 a has an outlet 2502 a andoversized trough 2404 b has an outlet 2502 b. Outlets 2502 a and 2502 bare similar to, and serve a similar function as, outlet 180 of oversizedcollection trough 176, described above with reference to FIGS. 13A and13B. Undersized collecting assembly 2402 further includes discharge port2504 that has a similar structure to, and serves a similar function as,discharge port 169 of undersized collecting assembly 160, describedabove with reference to FIGS. 11A and 11B. FIG. 25 also shows a view ofcollecting chute 2506 of undersized collecting assembly 2402, which issimilar to, and serves a similar function as, collecting chute 166,described above with reference to FIGS. 11A and 11B.

FIG. 26 is a further top perspective view of collecting apparatus 2400of FIGS. 24 and 25 , according to one or more embodiments of the presentdisclosure. In this view, both oversized collecting troughs 2404 a and2404 b are shown. Further, angled surface 2410 of FIG. 24 is shown inFIG. 26 as having a first angled portion 2602 a and a second angledportion 2602 b. First angled portion 2602 a is sloped downwardly towardoversized collecting trough 2404 a and second angled portion 2602 b issloped downwardly toward oversized collecting trough 2404 b.

As described in greater detail below with reference to FIGS. 27 to 29 ,oversize materials flowing over end plate 428 of screening deck assembly400 (e.g., see FIG. 5 ) may fall on first angled portion 2602 a or onsecond angled portion 2602 b. In this way, oversized materials that landon first angled portion 2602 a are diverted to oversized collectingtrough 2404 a while oversized materials that land on second angledportion 2602 b are diverted to oversized collecting trough 2404 b. Thus,angled portions 2602 a and 2602 b respectively play a similar role tochambers 174 and 174′ of oversized collecting chutes 171, describedabove with reference to FIG. 12B. As described above with reference toFIG. 24 , collecting apparatus 2400 further includes divertingstructures 2412 that act to guide oversized materials toward oversizedcollecting troughs 2404 a and 2404 b and away from ducts 2406.

FIG. 27 is a side perspective view of the collecting the apparatus 2400of FIGS. 24, 25, and 26 with a plurality of installed screening deckassemblies 400, according to one or more embodiments of the presentdisclosure. In this configuration, oversized material flowing from a topscreening surface of screening deck assemblies (e.g., see FIG. 5 ) isdirected by first 2602 a and second 2602 b (e.g. see FIG. 26 ) angledportions of angled surface 2410 (e.g., see FIG. 24 ). Divertingstructures 2412 further act to guide oversized materials towardoversized collecting troughs 2404 a and 2404 b and away from ducts 2406,as described above with reference to FIGS. 24 and 26 .

FIG. 28 is a further side perspective view of collecting apparatus 2400with installed screening deck assemblies 400 of FIG. 27 , according toone or more embodiments of the present disclosure. Each screening deckassembly 400 includes a first screening deck 410, a second screeningdeck 420, and a wash tray 440, as described above with reference toFIGS. 5 to 10 . When in operation, material to be screened is depositedon first screening deck 410 by feed outlet ducts 133 (e.g., see FIG. 2and related description above). Vibration causes material to flow overfirst screening deck 410, over wash tray 440, and onto second screeningdeck 420, as described above with reference to FIGS. 5 to 10 .

Undersized material flows through screens 409 and 419 (e.g., see FIGS.5, 15, 16A, and 16B and related description above) and is collected byducts 2406 of undersized collecting assembly 2402 (e.g., see FIG. 24 ).Oversized materials remain on a screening surface of screening decks 410and 420 and are discharged over lower end plate 428 of screening deck420 by vibration, as described in greater detail above with reference toFIG. 5 . After leaving lower end plate 428, oversized materials then hitone of the first 2602 a or second angled portion 2602 b (e.g., see FIG.26 ) and are thereby directed to respective oversize collecting troughs2404 a or 2404 b (e.g., see in FIG. 26 ) as described above.

FIG. 29 is a further side perspective view of the collecting apparatuswith installed screening deck assemblies of FIGS. 27 and 28 , accordingto one or more embodiments of the present disclosure. This view showsfurther structural details of screening decks 410 and 420 and should becompared with FIG. 6 , described in greater detail above. In thisregard, upper screening deck 410 includes a first plurality of stringers414 and lower screening deck 420 includes a second plurality ofstringers 424. First plurality of stringers 412 is supported by ribs 412and the second plurality of stringers 424 are supported by ribs 422.First 414 and second 424 pluralities of stringers provide mechanicalsupport for screens 409 and 419 (e.g., see FIGS. 5 and 15 and relateddescription above). Screens 409 and 419 (e.g., see FIGS. 5, 14, and 15 )may be respectively installed on screen decks 410 and 420 and held inplace by a tensioning mechanism (e.g., tensioning strip 455 of FIG. 14 )that exerts tension to screens 409 and 419 along a front-to-backdirection, that is, in the same direction that material to be screenedflows across the screen deck assembly 400.

Conditional language, such as, among others, “can,” “could,” “might,” or“may,” unless specifically stated otherwise, or otherwise understoodwithin the context as used, is generally intended to convey that certainimplementations could include, while other implementations do notinclude, certain features, elements, and/or operations. Thus, suchconditional language generally is not intended to imply that features,elements, and/or operations are in any way required for one or moreimplementations or that one or more implementations necessarily includelogic for deciding, with or without user input or prompting, whetherthese features, elements, and/or operations are included or are to beperformed in any particular implementation.

This specification and annexed drawings disclose vibratory screeningmachines that include stacked screening deck assemblies. It is, ofcourse, not possible to describe every conceivable combination ofelements for purposes of describing the various aspects of thedisclosure. Thus, while embodiments of this disclosure are describedwith reference to various implementations and exploitations, it is notedthat such embodiments are illustrative and that the scope of thedisclosure is not limited to them. Those of ordinary skill in the artcan recognize that many further combinations and permutations of thedisclosed features are possible. As such, various modifications can bemade to the disclosure without departing from the scope or spiritthereof. In addition or in the alternative, other embodiments of thedisclosure can be apparent from consideration of the specification andannexed drawings, and practice of the disclosure as presented herein. Itis intended that the examples put forward in the specification andannexed drawings be considered, in all respects, as illustrative and notrestrictive. Although specific terms are employed herein, they are usedin a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. A vibratory screening machine, comprising: anouter frame; an inner frame connected to the outer frame; a vibratorymotor assembly attached to the inner frame such that the vibratory motorassembly vibrates the inner frame; a plurality of screen deck assembliesattached to the inner frame and configured in a stacked arrangement,each one of the plurality of screen deck assemblies configured toreceive replaceable screen assemblies; an undersized material dischargeassembly configured to receive materials that pass through the screenassemblies, wherein the undersized material discharge assembly includesan undersized material collection channel in communication with each oneof the plurality of screen deck assemblies; and an oversized materialdischarge assembly comprising at least one oversized material collectionchannel in communication with each of the plurality of screen deckassemblies and configured to receive oversized materials that pass thatdo not pass through the screen assemblies and that pass over dischargeends of the plurality of screen deck assemblies, wherein the oversizedmaterial discharge assembly includes at least one deflector that isconfigured to alter a direction of movement of at least some of theoversized materials such that the oversized materials are directed intothe at least one oversized material collection channel.
 2. The vibratoryscreening machine according to claim 1, wherein the at least onedeflector is configured to alter a direction of movement of oversizedmaterials on top surfaces of the screen assemblies.
 3. The vibratoryscreening machine according to claim 1, wherein the at least onedeflector is located below the plurality of screen deck assemblies andis configured to convey oversized materials that have passed overdischarge ends of the plurality of screen deck assemblies away from theundersized material collection channel and toward the at least oneoversized material collection channel.
 4. The vibratory screeningmachine according to claim 1, wherein the oversized material dischargeassembly comprises a first oversized material collection channel and asecond oversized material collection channel.
 5. The vibratory screeningmachine according to claim 4, wherein the undersized material collectionchannel, the first oversized material collection channel and the secondoversized material collection channel are located beneath the pluralityof screen deck assemblies, and wherein the undersized materialcollection channel is located between the first oversized materialcollection channel and the second oversized material collection channel.6. The vibratory screening machine according to claim 5, wherein the atleast one deflector causes oversized materials at central portions ofthe discharge ends of the screen deck assemblies to be redirectedtowards side edges of the discharge ends of the screen deck assemblies.7. The vibratory screening machine according to claim 6, wherein the atleast one deflector comprises a plurality of deflectors, each deflectorbeing located adjacent a discharge end of a screen deck assembly.
 8. Thevibratory screening machine according to claim 5, wherein the at leastone deflector is located below the screen deck assemblies, and whereinthe at least one deflector is configured to cause oversized materialsthat have passed over discharge ends of the screen deck assemblies to bedirected away from the undersized material collection channel and intothe first and second oversized material collection channels.
 9. Thevibratory screening machine according to claim 8, wherein each at leastone deflector comprises first and second surfaces that cause oversizedmaterials that have passed over discharge ends of the screen deckassemblies to be directed away from the undersized material collectionchannel and towards the first and second oversized material collectionchannels.
 10. The vibratory screening machine according to claim 1,wherein each one of the plurality of screen deck assemblies includes afirst screen assembly, a second screen assembly and a trough locatedbetween the first screen assembly and the second screen assembly. 11.The vibratory screening machine according to claim 10, wherein thetrough includes an Ogee-weir structure.
 12. The vibratory screeningmachine according to claim 1, wherein the screen assemblies are securedto the screen deck assemblies by tensioning the screen assemblies in adirection that a material to be screened flows across the screenassemblies.
 13. The vibratory screening machine according to claim 12,further comprising a screen tensioning system that includes tensioningrods that extend substantially orthogonal to the direction of flow ofthe material being screened, wherein the tensioning rods are configuredto mate with a portion of a screen assembly and to tension the screenassembly when rotated.
 14. A method of screening a material, comprising:feeding the material into a vibratory screening machine comprising: aplurality of screen deck assemblies that are configured in a stackedarrangement, each one of the plurality of screen deck assembliesconfigured to receive replaceable screen assemblies, an undersizedmaterial discharge assembly configured to receive materials that passthrough the screen assemblies, wherein the undersized material dischargeassembly includes an undersized material collection channel incommunication with each one of the plurality of screen deck assemblies,an oversized material discharge assembly comprising at least oneoversized material collection channel in communication with each of theplurality of screen deck assemblies and configured to receive oversizedmaterials that pass that do not pass through the screen assemblies andthat pass over discharge ends of the plurality of screen deckassemblies, and a deflector that is configured to alter a direction ofmovement of at least some of the oversized materials such that theoversized materials are directed into the at least one oversizedmaterial collection channel; and screening the materials such thatundersized materials pass through the replaceable screen assemblies andflow into the undersized material collection channel and such thatoversized materials that flow over the discharge ends of the pluralityof screen deck assemblies flow into the at least one oversized materialcollection channel, wherein the deflector alters a direction of movementof at least some of the oversized materials so that the oversizedmaterials flow into the at least one oversized material collectionchannel.
 15. The method of claim 14, wherein the at least one deflectoralters a direction of movement of oversized materials on top surfaces ofthe screen assemblies.
 16. The method of claim 14, wherein the at leastone deflector is located below the plurality of screen deck assembliesand causes oversized materials that have passed over discharge ends ofthe plurality of screen deck assemblies to move away from the undersizedmaterial collection channel and toward the at least one oversizedmaterial collection channel.
 17. The method of claim 14, wherein theoversized material discharge assembly comprises a first oversizedmaterial collection channel and a second oversized material collectionchannel.
 18. The method of claim 17, wherein the undersized materialcollection channel, the first oversized material collection channel andthe second oversized material collection channel are located beneath theplurality of screen deck assemblies, and wherein the undersized materialcollection channel is located between the first oversized materialcollection channel and the second oversized material collection channel.19. The method of claim 18, wherein the at least one deflector causesoversized materials at central portions of the discharge ends of thescreen deck assemblies to be redirected towards side edges of thedischarge ends of the screen deck assemblies.
 20. The method of claim18, wherein the at least one deflector is located below the screen deckassemblies, and wherein the at least one deflector is configured tocause oversized materials that have passed over discharge ends of thescreen deck assemblies to be directed away from the undersized materialcollection channel and into the first and second oversized materialcollection channels.
 21. The method of claim 20, wherein each at leastone deflector comprises first and second surfaces that cause oversizedmaterials that have passed over discharge ends of the screen deckassemblies to be directed away from the undersized material collectionchannel and towards the first and second oversized material collectionchannels.
 22. The method of claim 14, wherein each one of the pluralityof screen deck assemblies includes a first screen assembly, a secondscreen assembly and a trough located between the first screen assemblyand the second screen assembly.
 23. The method of claim 22, wherein thetrough includes an Ogee-weir structure.
 24. The method of claim 14,wherein the screen assemblies are secured to the screen deck assembliesby tensioning the screen assemblies in a direction that a material to bescreened flows across the screen assemblies.
 25. The method of claim 24,wherein the vibratory screening machine further comprises a screentensioning system that includes tensioning rods that extendsubstantially orthogonal to the direction of flow of the material beingscreened, wherein the tensioning rods are configured to mate with aportion of a screen assembly and to tension the screen assembly whenrotated.